System and method for panelized, superinsulated building envelopes

ABSTRACT

Panelized wall and roof structures for constructing energy efficient buildings. The panelized structures have a structural layer with insulation, an airtight layer providing a primary air barrier and a vapor retarder exterior to the structural layer, a vapor open blanket layer including insulation and attached to the structural layer via structural screws, a weather resistant barrier provided exterior to the blanket layer and including an airtight, water-repelling, vapor-open fabric, and a rain screen provided exterior to the weather resistant barrier and including a drainage plane for channeling moisture away from the weather resistant barrier.

CROSS REFERENCE TO RELATED APPLICATIONS

The present invention claims priority to U.S. Provisional ApplicationSer. No. 62/197,931 filed on 28 Jul. 2015 and herein incorporated byreference in its entirety.

FIELD OF THE INVENTION

The present invention relates to the field of construction of energyefficient buildings. Moreover, the present invention relates topanelized, superinsulated building systems and methods.

BACKGROUND OF THE INVENTION

In the design and construction of buildings, it is well known thatenergy efficiency and building insulation go hand in hand. Accordingly,numerous types of insulation systems and methods exist. Within typical“stick built” construction using framed lumber, voids are created withinwalls. In such exterior walls, these voids are often filled withfiberglass, cellulose-based, or foam material which have variedinsulative value. Vapor barriers are typically added to such exteriorwalls in order to enhance the insulative effect. However, due to thenature of such framed lumber, thermal bridging often detrimentallyoccurs to facilitate heat transfer within walls. As well, a variety ofleakage points exist due to difficulties inherent to current vaporbarrier technology.

Improvements have been attempted in the form of structural insulatedpanels (SIPs) which are a high performance building system forresidential and light commercial construction. The panels consist of aninsulating foam core (e.g., extruded polystyrene XPS or expandedpolystyrene EPS foam) sandwiched between two structural facings,typically oriented strand board (OSB). SIPs are manufactured underfactory controlled conditions and can be fabricated to fit nearly anybuilding design. The result is a building system that is extremelystrong, energy efficient and cost effective. Disadvantageously however,standard SIP technology typically requires spline joints which connectthe panels together while allowing thermal bridging to occur.

In order for more new construction to be energy efficient and durableagainst the moisture-related problems that are sometimes associated withthick, airtight assemblies, new construction methods are required. Theassemblies that will perform best from energy and resiliency viewpointsare inherently complex, time-consuming to assemble, and requirespecialized training to execute effectively.

It would be advantageous to obviate or mitigate these disadvantages suchthat heat transfer between building interiors and exteriors, thermalbridging, and leakage are substantially reduced or eliminated.

SUMMARY OF THE INVENTION

The present invention provides a system and method for panelized,superinsulated building envelopes that reduces or substantiallyeliminates many problems in building construction including heattransfer between building interiors and exteriors, thermal bridging, andleakage. The present invention reduces contributions to climate changedue to wasted energy in the built environment. Difficulties in qualitycontrol for and time required on site to build complicated buildingenvelope assemblies are minimized by way of the present invention.

The present invention reduces moisture-related issues, includingreducing problems from mold inside building envelopes that are notvapor-open to the exterior and improving cladding longevity in buildingassemblies without a rain screen detail. The present invention alsoreduces moisture-related problems, including mold, in buildingassemblies insulated to higher levels than required by building codes.

The present invention provides effective air-sealing of buildingassembly panels, maintains integrity of the air barrier during and afterthe construction process, and provides enhanced insulating of “marriagejoints” between building assembly panels.

The present invention overcomes difficulties in providing continuity ofa weather resistant barrier between building assembly panels andresolves both problems related to vapor open construction of exteriorand interior corners and also difficulties in building exterior andinterior corners without thermal bridges.

The present invention also provides connections from wall to roof and atwindow and door supports that are free of thermal bridging.

The present invention enables a window assembly allowing for drainageinto the rain screen, behind the cladding.

The present invention provides a service cavity on the inside of abuilding envelope assembly.

The present invention also provides effective insulation and air sealingof bother concrete slab foundations as well as foam-free pierfoundations.

The present invention provides these benefits and solves these problemsby using specific assemblies constructed in a controlled shopenvironment by skilled workers, then assembled on site using prescribeddetails. Anyone building a new home, new commercial or institutionalbuilding, or building significant additions to existing structures maybenefit from the present system and method. Because most of the cost isin building and installing the panels, with travel costs as acomparatively minor expense, the system and method of the presentinvention effectively enables building houses in any location so as tobring low-energy, high-performance buildings to anyone constructing abuilding.

According to a first aspect of the invention there is provided a systemfor constructing an energy efficient building, the system includes: atleast one panelized structure having a structural layer including afirst set of voids and located at an inner area of the at least onepanelized structure, the inner area being adjacent to intended livingspace of the energy efficient building, an airtight layer formed by afirst sheathing layer providing a primary air barrier and a vaporretarder exterior to the structural layer, a blanket layer locatedexterior to the first sheathing layer and formed by a plurality ofvertical members with a second set of voids located between each of thevertical members, a weather resistant barrier located exterior to theblanket layer and including a second sheathing layer formed by anairtight, water-repelling, vapor-open fabric, a rain screen locatedexterior to the weather resistant barrier, the rain screen beingadjacent to outdoor space external to the energy efficient building andincluding a drainage plane internal thereto, the drainage plane forchanneling moisture away from the weather resistant barrier; insulationfor placement within the structural layer and the blanket layer; andwherein the at least one panelized structure is air-sealed and insulatedwithin the first and second sets of voids after installation.

According to a second aspect of the present invention there is provideda panelized wall structure for constructing an energy efficientbuilding, the panelized wall structure includes: a structural layerhaving a first set of voids and located at an inner area of thepanelized wall structure, the inner area being adjacent to intendedliving space of the energy efficient building; an airtight layer formedby a first sheathing layer providing a primary air barrier and a vaporretarder exterior to the structural layer; a blanket layer locatedexterior to the first sheathing layer and formed by a plurality ofvertical members with a second set of voids located between each of thevertical members; a weather resistant barrier located exterior to theblanket layer and including a second sheathing layer formed by anairtight, water-repelling, vapor-open fabric; and a rain screen locatedexterior to the weather resistant barrier, the rain screen beingadjacent to outdoor space external to the energy efficient building andincluding a drainage plane internal thereto, the drainage plane forchanneling moisture away from the weather resistant barrier.

According to a third aspect of the present invention there is provided apanelized roof structure for constructing an energy efficient building,the panelized roof structure for constructing an energy efficientbuilding, the panelized roof structure includes: a structural layerhaving a first set of voids and located at an inner area of thepanelized roof structure, the inner area being adjacent to intendedliving space of the energy efficient building; an airtight layer formedby a first sheathing layer providing a primary air barrier and a vaporretarder exterior to the structural layer; a blanket layer locatedexterior to the first sheathing layer and formed by a plurality ofvertical members with a second set of voids located between each of thevertical members; a weather resistant barrier located exterior to theblanket layer and including a second sheathing layer formed by anairtight, water-repelling, vapor-open fabric; and a rain screen locatedexterior to the weather resistant barrier, the rain screen beingadjacent to outdoor space external to the energy efficient building andincluding a drainage plane internal thereto, the drainage plane forchanneling moisture away from the weather resistant barrier.

Other aspects and features of the present invention will become apparentto those ordinarily skilled in the art upon review of the followingdescription of specific embodiments of the invention in conjunction withthe accompanying figures.

BRIEF DESCRIPTION OF THE DRAWINGS

Embodiments of the present invention will now be described, by way ofexample only, with reference to the attached Figures, wherein:

FIG. 1 is a cross sectional side view of a south facing buildingsidewall from ground to roof which illustrates various building partswhere the present invention may be embodied.

FIG. 2 is a schematic cross-sectional side view showing wall o raft slabdetails incorporating the present invention.

FIG. 3 is a schematic cross-sectional side view showing a heatedbasement detail having trussed flooring and incorporating the presentinvention.

FIG. 4 is a schematic cross-sectional side view showing an unheatedbasement detail having trussed flooring and incorporating the presentinvention.

FIG. 5 is a schematic cross-sectional side view showing an unheatedbasement detail with I-beam supported flooring and incorporating thepresent invention.

FIG. 6 is a schematic cross-sectional top view showing an exteriorcorner detail incorporating the present invention.

FIG. 7 is a schematic cross-sectional top view showing marriage jointdetail incorporating the present invention.

FIG. 8 is a schematic cross-sectional top view showing an interiorcorner detail incorporating the present invention.

FIG. 9 is a schematic cross-sectional top view showing an exterior wallto partition wall detail incorporating the present invention.

FIG. 10A is a schematic cross-sectional side view showing a door headdetail incorporating the present invention.

FIG. 10B is a schematic cross-sectional side view showing a door sill toslab detail incorporating the present invention.

FIG. 11B is a schematic cross-sectional plan view showing a fixed windowdetail incorporating the present invention.

FIG. 11B is a schematic cross-sectional plan view showing an operablewindow detail incorporating the present invention.

FIG. 12A is a schematic cross-sectional side view showing a fixed windowhead detail incorporating the present invention.

FIG. 12B is a schematic cross-sectional plan view showing a fixed windowsill detail incorporating the present invention.

FIG. 12C is a schematic cross-sectional side view showing an operablewindow head detail incorporating the present invention.

FIG. 12D is a schematic cross-sectional plan view showing an operablewindow sill detail incorporating the present invention.

FIG. 13 is a schematic cross-sectional side view showing floor to floorgable wall marriage detail incorporating the present invention.

FIG. 14 is a schematic cross-sectional view through a panelized roofincorporating the present invention.

FIG. 15 is a schematic cross-sectional view through a panelized roofshowing eave detail and incorporating the present invention.

FIG. 16 is a schematic cross-sectional view through a panelized roofshowing ridge detail and incorporating the present invention.

FIG. 17 is a schematic cross-sectional view through a trussed roofincorporating the present invention.

FIG. 18 is a schematic cross-sectional view through a low slope pitchroof incorporating the present invention.

DETAILED DESCRIPTION

The present invention is a system and method which provides panelized,superinsulated building envelopes. In general, panel sections inaccordance with the invention are shop-fabricated as completedassemblies or as partial assemblies and are installed as components on abuilding site. Assemblies in accordance with the present invention mayinclude wall, roof, and floor assemblies. Such assemblies provide a newand useful alternative to standard SIPs such that the inventiveassemblies are both thermal bridge free and foam free.

All assemblies in accordance with the present invention are designed andconstructed to be highly energy efficient, resilient and durable, and tomeet the voluntary International Passive House building energy standardand/or the Passive House Institute of the United States building energystandard. It should be understood that all parts of each buildingcomponent or assembly are equally important to the overall inventivesystem and method in order to meet ideal building envelope performancegoals and the aforementioned energy standard.

With specific reference to the figures below, it should be understoodthat like parts exists in more than one figure. As such, each like partis numbered identically when like structures are used throughout thevarious embodiments. For clarity, only the first occurrence of suchstructures may be described in detail where subsequent figures may notinclude a repeated description of like structures.

With reference to the drawings, FIG. 1 is a compilation whichillustrates a variety of assemblies (shown in cross section) which, oncejoined together on a building site with typical other buildingcomponents, form a panelized, superinsulated building envelope embodyingthe invention. The inventive aspects of the present invention thereforeinclude the inventive assemblies, the building system incorporating theassemblies, and the method by which the assemblies thereby form thepanelized, superinsulated building envelope. In particular, FIG. 1 is across sectional side view of a south facing building sidewall fromground to roof which illustrates various building parts where thepresent invention may be embodied. Here, a ground level section 4,mid-floor section 5, and roof section 6 can be seen with first floorwindow 3 and second floor window 2 located between sections. Theinventive components in FIG. 1 include panel assemblies 4 a, 5 a, 5 c,and 6 c which will be further described in more detail related to FIGS.2 through 18. Commonly understood components such as foundation 4 b,suspended flooring 5 d, roofing structure 6 d, exterior roofing 6 a arealso shown and which are pertinent to the present discussion as theyprovide context in terms of implementation of the present invention,though are not of particular importance in their specific design asconfigurations may change given the particular building architectureand/or site requirements. As well, exterior overhangs 5 b, 6 b to shielddirect sunlight rays (shown as dotted line 1) are provided as shadingdevices which may be sized and located so as to provide solar shading ofthe exposed window frame.

With regard to FIG. 2, there is shown a schematic cross-sectional sideview showing wall to raft slab details incorporating the presentinvention. Here, a panelized wall section in accordance with theinvention is secured atop a concrete slab 25. Beneath the slab 25 isfoundation insulation 24 preferably formed from 12-inch type II boratetreated expanded polystyrene (EPS) foam insulation. Mating pieces ofadditional foundation insulation 20 surround the periphery of the slab25 and are placed under the overhanging end sheathing 18. The additionalfoundation insulation is preferably formed from 12-inch type IX boratetreated EPS foam insulation. As shown, typical groundwork is providedincluding large composition structural fill 21 and perimeter drain 23run to daylight with a fabric 22 overlaid atop the drain 23 such thatthe filter fabric separates granular fill from larger compositestructural fill over 4-inch.

As mentioned above, the present invention may be incorporated within abuilding having a raft slab. As seen in FIG. 2, a concrete slab-on-gradefoundation is a raft slab whereby blocks made from borate-treated EPS(expanded polystyrene) are provided below the concrete. Borate-treatedEPS has been found to be the most durable and benign plastic foam forthis location. The EPS blocks may be configured using dado and tenonjoinery so as to easily lock together block pieces. The interlockedblocks therefore protect the concrete slab from thermal loss, isolatingthe interior from radon and water vapor, and acting as a concreteform—all in one system. Once the raft slab insulation is placed, an8-inch steel-reinforced concrete slab is poured which is thick enoughthat separate footings are not required under point loads. The floor ispolished and sealed as a finished floor, or covered with anothermaterial. The present invention incorporating such foundation system iscertified by the International Passive House Institute to be free ofthermal bridging, with a U value of 0.12 W/m²K (0.021 Btu/hr ft² ° F.),≈R 47.6.

During installation, it is advantageous to install the walls on top ofthe foundation vapor barrier to complete the air barrier. As well, theuse of adhesive sealant will complete the air barrier connection fromwall to foundation.

The panelized wall section portion of FIG. 2 includes elements which canbe grouped into five (5) basic categories. Indeed, all panelizedsections discussed herein below in accordance with the present inventionincludes elements that may also be grouped similarly into such five (5)basic categories. These categories of elements include the structurallayer, the airtight layer, the blanket layer, the weather resistantbarrier, and the rain screen.

The structural layer forms an inner, structural wall. In FIG. 2, thiscan be seen by internal wall 34 which is preferably 2×4 studs arranged24-inch on center of #2 SPF (spruce-pine-fir) or better per NELMA(Northeastern Lumber Manufacturers Association). The base of internalwall 34 includes a continuous 2×4 bottom plate 26. The bottom plate 26secures the panelized wall section to the slab 25 via an anchor bolt 28.The structural layer may also include internal surfacing of gypsumsheetrock 33 or any suitable interior surfacing product for the givenimplementation. Within the voids between studs of the internal wall 34,there is also provided mineral wool insulation 32.

The interior, structural wall 34 carries all structural loads, with mostinsulation on the exterior, though it is left uninsulated, as a “servicecavity,” until after the building envelope is complete so as tofacilitate panel attachments, mechanical, and electrical work.

The airtight layer provides a structural diaphragm that is also theprimary air barrier and vapor retarder on the outside of the structurallayer. In terms of FIG. 2, this provided by the continuous 2×4 bottomplate 26 being wrapped with a weathertight tape such as Tescon Extoseal®sill tape available from Pro Clima® of Schwetzingen, Germany or anysuitable weathertight tape. As well, the anchor bolt 28 is set in epoxyadhesive 27 to ensure weathertight seal of bottom plate 26 to the slab25. A first sheathing layer 30 is provided adjacent to the internal wall34. This first sheathing layer 30 is preferably constructed of asuitable weathertight coated OSB (oriented strand board) such as7/16-inch ZIP® sheathing available from Huber Engineered Woods LLC ofCharlotte, N.C.

The first sheathing layer 30 is rendered airtight with all joints andnail holes taped with a suitable weatherproof taping such as TesconVana® adhesive tape with fleece backing available from Pro Clima® or anysuitable weathertight tape. Lastly, a vapor barrier 19 is provided toseparate the slab 25 from the exterior insulation 20, 24. The vaporbarrier 19 may be a continuous ten (10) mil polyethylene sheet or anysuitable material that functions as air barrier and capillary break.Thus, a contiguous airtight layer is formed by the first sheathing layer30 and vapor barrier 19 which are connected in a weathertight manner atthe continuous bottom plate 26. Moreover, it is beneficial that theairtight layer is placed in a protected location, internal to thepanelized wall structure.

The blanket layer is an exterior insulating layer that includes verticalmembers filled between with insulation. It should be noted that theblanker layer is vapor open. As shown in FIG. 2, each vertical member isan I-joist 29. Each I-joist 29 is preferably an 11⅞ inch I-joistarranged 24 inches on center with SPF flanges and OSB webs. Between eachI-joist 29 is a void which is filled with a dense pack celluloseinsulation 14 or similar suitable insulating material. The blanket layeris held to the structural layer by suitable screws 31 as shown and whichare preferably 5/16″×4″ RSS™ lag screws fastened at two feet on centerand staggered. RSS™ lag screws are a rugged structural screw made ofspecially hardened steel and available from GRK Fasteners of Schaumburg,Ill.

It should be understood that the “I-joists” referred to herein are anengineered wood product consisting of solid wood or laminated woodflanges and structural sheet material such as plywood or OSB as the weband which are advantageously placed outside the structural wall and airbarrier, as support for cladding and insulation. Attaching the I-joiststo the structural wall with structural screws thereby also is anadvantage as the panelized wall structure relies upon screws as the onlystructural support for the blanket layer. For purposes allowing airevacuation when installing blown insulation, holes may be drilled in theI-joists of the blanket layer and covered with air-permeable mesh.Cellulose insulation may be installed more densely than normal, at 4.0to 4.25 pounds per cubic foot, to ensure that such insulation remains inplace during transport and for the life of the building.

The blanket layer is insulated with cellulose to a minimum density of4.0 lbs/ft³, denser than typical to prevent settling in the presentinvention's larger-than-typical insulation cavities. The hygroscopicnature of cellulose insulation serves as a moisture buffer and a mineralborate additive makes the cellulose fireproof as well as resistant topests. Testing has shown that over time, the moisture content within thewalls fluctuates slightly, tracking environmental conditions, but thatit stays far below the levels required for mold growth.

With continued reference to FIG. 2, the weather resistant barrier isformed partly by a second sheathing layer 11. This second sheathinglayer 11 is made of an airtight, water-repelling, vapor-open fabric thatis resistant to outdoor weather. The second sheathing layer 11 should bea vapor-variable product which protects against water vapor movementwith a low permeance (e.g., of 0.17 Perms, on the cusp of a class 1 andclass 2 vapor retarder, but opens to 13.20 Perms (a class 3 vaporretarder)) which allows for drying in the presence of high moisturecontent. The membrane is reinforced to allow it to support dense-packedcellulose. Preferably, the second sheathing layer 11 is fabricated froma continuous Solitex Mento Plus® weather resistant barrier from ProClima® with all joints taped with Tescon Vana® adhesive tape with fleecebacking available from Pro Clima® or any suitable weathertight tape.Additionally, the overhanging end sheathing 18 is also resistant tooutdoor weather. Preferably, the overhanging end sheathing 18 isconstructed similar to the first sheathing layer 30 and is preferablyconstructed of a suitable weathertight coated OSB (oriented strandboard) such as 7/16-inch ZIP® sheathing and rendered airtight with alljoints and nail holes taped with a suitable weatherproof taping such asTescon Vana® adhesive tape or any suitable weathertight tape. Thus, thesecond sheathing layer 11 and end sheathing 18 as a bottom plate toencapsulate the blanket layer. Moreover, it should be understood thatsheet goods (plywood or OSB) at the top and bottom of the I-joists 29are provided as top and bottom plates to create a cavity for blowninsulation.

The fifth category of grouped elements of the panelized wall section inaccordance with the present invention is the rain screen which includesthe outermost parts shown in FIG. 2 adjacent the exterior of the secondsheathing layer 11. Vertical strapping 12 is provided over the secondsheathing layer 11 and preferably formed by 1×3 SPF arranged 12″ oncenter. Upon the vertical strapping 12 is secured horizontal strapping13 preferably formed by 1×3 SPF arranged 24′ on center. The verticalstrapping 12 and horizontal strapping 13 therefore form two layers offurring material in a “flying batten” configuration to create a freelydraining “rain screen” drainage plane. The flying battens are off-layoutstrips formed of the 1×3 strapping as mentioned and are used to keep thesecond sheathing layer 11 from pushing too far into the rain screenduring and after cellulose installation. The final outer layer of siding15 is provided in any typical manner such as standard ¾ inch wood sidingor as desired for the given building's exterior decor requirements.

The vertical strapping 12 provides a gap at the bottom end thereof wherewall vent 16 is inserted. Preferably, the wall vent 17 is SV-5 SidingVent available from Cor-A-Vent, Inc. of Mishawaka, Ind. or any suitableheat-resistant webbing made from profile extruded polypropylene plasticthat functions as a drainage mat for moisture collected in the areabehind the siding 15. It should also be noted that a termite shield 17may be provided as is typical to ward off wood eating insects. It shouldalso be noted that it is advantageous that the I-joists 29 are notbearing the on the concrete slab 25.

Having discussed above what is fundamentally the basic component of thepresent invention, namely a panelized wall section, it should beunderstood that the following discussion of subsequent FIGS. 3 through18 are combinations of a variety of configurations of panelized wallsections in accordance with the present invention. As such, they aremeant as illustrative of some of the possible variations of the presentinvention, though other combinations and sub-combinations may be wellwithin the intended scope of the present invention without straying fromthe invention.

FIG. 3 includes several identical parts as previously shown anddescribed with regard to the panelized wall section portion of FIG. 2.As such, those identical parts will not be again described, but ratherthe differentiated parts will be discussed with regard to FIG. 3. Morespecifically, FIG. 3 shows a schematic cross-sectional side view showinga heated basement detail having trussed flooring and incorporating thepresent invention. Here, a section of suspended flooring structure isprovided above a heated basement. The suspended flooring structureincludes a rimboard 35 abutting the first sheathing layer 30. Web joists37 are situated against the rimboard 35 and the bottom ends of each webjoist 37 rest upon a sole plate 38. Subfloor 36 is provided in a knownmanner across each web joist 37. In this configuration, it should benoted that the internal wall 34 of the panelized wall section residesatop the subfloor.

As the sole plate 38 is within the heated building envelope, it need notbe wrapped as was the bottom plate 26 shown in FIG. 2. The sole plate 38is secured in a typical fashion via anchor bolt 28 to the foundationwall 39. Likewise, in typical fashion, a footing 43 supports thefoundation wall 39. A break 100, common to this and several followingfigures, in the foundation wall 39, foundation insulation 24, and fill21 is shown to indicate that the height of the foundation structure maybe longer than is shown. As the foundation insulation 24 is foam whichwould otherwise degrade when exposed to sunlight and weather, a layer ofcement board 40 will normally be provided and typically will include aparge coat.

With continued reference to FIG. 3 and forming part of the weatherresistant barrier, there is provided waterproofing 41 on the exterior ofthe foundation wall 39. Such waterproofing 41 is typically a fluidprovided membrane known in the art. Likewise, a capillary break 42 willbe provided between the foundation wall 39 and the footing 43. Theweather resistant barrier is thus formed in the embodiment of FIG. 3 bythe first sheathing layer 30 contiguously with the waterproofing 41,capillary break 42, and vapor barrier 19.

FIG. 4 is similar to FIG. 3 except that the basement area is unheated.Specifically, FIG. 4 is a schematic cross-sectional side view showing anunheated basement detail having trussed flooring and incorporating thepresent invention. In such configuration, the weather resistant barrierproviding the building's internal envelope excludes the basement area.Here, it should be noted that cellulose insulation 14 is provided withinthe suspended floor structure among each web joist 37. Moreover, amembrane 44 is provided under suspended floor structure against thebottom side of each web joist 37, running atop the sole plate 38, andsealed to the first sheathing layer 30. Such membrane 44 is preferably ahigh performance airtight vapor control layer such as Pro Clima® DAmembrane. Thus while the waterproofing 41, capillary break 42, and vaporbarrier 19 contiguously provide a barrier layer to the unheated basementarea, the weather resistant barrier in the configuration shown in FIG. 4is primarily provided by the membrane 44 and the first sheathing layer30.

FIG. 5 is similar to FIG. 4 except that the suspended floor structure ismore akin to the panelized wall section. Specifically, FIG. 5 is aschematic cross-sectional side view showing an unheated basement detailwith I-beam supported flooring and incorporating the present invention.The I-beams 46 are preferably 24 inches wide and placed 16 inches oncenter. The I-beams 46 are engineered wood joists such as TJI® Joistsavailable from Weyerhaeuser of Federal Way, Wash. A lower sheathinglayer 45 is provided on the underside of the I-beams 46 and isstructural in its function as well as forming part of the weatherresistant barrier in this embodiment. Like the first sheathing layer 30,the lower sheathing layer 45 is rendered airtight with all joints andnail holes taped with a suitable weatherproof taping such as TesconVana® adhesive tape with fleece backing available from Pro Clima® or anysuitable weathertight tape. In this embodiment, the primary airtightlayer is formed by the first sheathing layer 30 contiguously with thelower sheathing layer 45.

A corner connection between two panelized wall sections in accordancewith the present invention is shown in FIG. 6 as a schematiccross-sectional top view showing an exterior corner detail. Dotted line200 denotes the panel break between the two panelized wall sections.Here, the screws 31 can be seen attaching each I-joist 29 to studs in ofthe internal walls 34 so as to attach the blanket layer to thestructural layer. Because such screws 31 can effectively break theairtight layer, portions of taping 50 are provided suitable to preventleakage at those locations. Taping 50 a is also provided at the exteriorconnection between panelized wall sections.

With further regard to FIG. 6, the ends of each panelized wall sectionscan be seen to include insulation board 49 which is light weight stonewool insulation board such as ProRox® SL 960 made by ROXUL INC. ofMilton, Ontario. Structural integrity of the panelized wall sections atthe corners is enhanced by the addition of corner sheathing 51 which maybe formed from a section of OSB. At the corner interior, structuralintegrity is provided by a C-stud formed by SPF studs 47 a, 47 b, 47 carranged in a C-configuration with a foam insulation 48 located withinany void created at the center of the C-stud. In this configuration, theairtight layer is formed by each first sheathing layer 30 and assured bytaping 50, 50 a.

At outside corners of walls, holding I-joists back from the ends of theairtight layer facilitates air sealing the vertical seam at the outsidecorner where the airtight layer of two panels meet. It may be useful tobuild one panel with extra second sheathing layer 11 to be unfurled andsealed to the adjacent panel after air sealing is complete. It is alsopossible to use a solid sheet of sheathing material on one face only ofthe rain screen layer, to facilitate panel connections while allowingthe wall to remain vapor-open at the adjacent face.

FIG. 7 is a schematic cross-sectional top view showing marriage jointdetail between panelized wall sections according to the presentinvention. Again, dotted line 200 denotes the panel break. Here, theinsulation boards 49 are seen to abut. As well, it should be understoodthat the second sheathing layer 11 is provided between abuttinginsulations boards 49. Taping 50 assures the airtight layer iscontiguous between each first sheathing layer 30. It may be also usefulin configurations such as this, where two wall panels meet in line, tobreak the panels off-layout (e.g., at 12″ for 24″ on center stud layout)to facilitate air sealing at those locations. As well, it may be usefulto build one panel with extra second sheathing layer 11 so as to beunfurled and sealed to the adjacent panel after air sealing is complete.

FIG. 8 is a schematic cross-sectional top view showing an interiorcorner detail incorporating the present invention. Here, an internalwall 34 is seen wrapping around an end of one panelized wall sectionwhere a C-stud is formed by studs 47 a, 47 b, and 47 c so as to providestructural integrity to the corner section. It should also be noted thatthe second sheathing layer 11 extends across both insulation boards 49.

At inside corners of walls, holding I-joists back from the inside cornermay allow workers to reach into the deep framing cavity to air-seal thevertical connection at the inside corner. It may be useful to build onepanelized wall section of the inside corner with extra second sheathinglayer 11 to be unfurled and sealed to the adjacent panel after airsealing is complete. As well, it may be useful at inside corners ofwalls to connect the rain screens at adjacent panels with an L-shapedassembly of OSB or other sheet stock, to provide a nailing base forsiding.

FIG. 9 is a schematic cross-sectional top view showing an exterior wallto partition wall abutting against one panelized wall section inaccordance with the present invention. In this configuration, theweather resistant barrier formed by first sheathing layer 30 remainsintact and uninhibited by a partition wall 34 a. Here, an end stud ofthe partition wall 34 a is joined to the panelized wall section by wayof a backer sheet 52 a which may be a section of plywood provided as abacking to drywall 33 and into which the end stud of partition wall 34 amay be suitably fastened by way of screws.

FIGS. 10A and 10B illustrate a sliding glass doorway within a panelizedwall section embodying the present invention. In particular, FIG. 10Ashows a schematic cross-sectional side view showing a door head detailwhile FIG. 10B is a schematic cross-sectional side view showing a doorsill to slab detail.

With reference to FIG. 10A, a nailer 52 b is shown which may be formedby a 1½″×1½″ section of SPF and to which a plywood buck 59 may besuitably fastened. The plywood buck 59 is a section of plywood suitablywrapped with a weathertight tape and creating a window buck and which istaped via taping 50 to a header 60 to create a contiguous air barrier aspart of the overall weather resistant barrier. The header 60 providesstructural integrity to the door opening and is integrated into the edgeof internal wall 34 adjacent the plywood buck 59. Outer door frame 57 aoperatively integrates with inner door frame 57 b in a known manner.

Window and door bucks (i.e., framing elements that surround and supportthe fenestration) may be of two main parts, inner bucks and outer bucks.The inner bucks are the structural support for the fenestration, and arefrom 1⅛″ to 1½″ thick, located inside the structural wall rough opening,extending to the inside of the structural wall. The outer bucks arethinner, from 7/16″ to ¾″ thick, placed outside and overlapping theinner bucks, extending to the outside of the blanket layer. The buckassembly is wrapped with one or more layers of solid wood to stiffen theassembly and to provide a nailing surface. The two-step buck assemblyserves to minimize thermal bridging, provides positive placement for thefenestration, and allows for insulation and drainage around the windowframe.

Glass 56 is preferably at least double paned with a warm edge “Swissspacer” 55 provided so as to proved enhanced insulative value. As well,triple-pane glass panels perform even better than the well-insulatedframes it is preferably that all exterior doors to be glass when used inthe context of the present invention. Gaps between the plywood buck 59and the outer 54 a and inner 54 b trim boards is filled respectivelywith foam type insulation 53 and 58 respectively. In particular,insulation 53 is preferably in the form of a high quality insulatingfoam panel which may be easily fashioned into the particular shape asshown, while insulation 58 may be in the form of water cured butyl firedurethane foam which may be injected into the corresponding space. Inthis manner, insulation 53 may be wrapped as shown with taping 50 tofurther enhance the airtight layer. It should be noted that windows areplaced near the center of the wall thickness which may provide aestheticbenefits as well as space for post-installation window treatments.

The high performance panelized wall sections of the present inventionrelatedly require high performance windows and exterior doors. Thepresent invention therefore works best in conjunction with exteriordoors that seal securely against air and water infiltration. As well,triple-pane glass panels are preferred. It is also preferable that allexterior doors to be glass when used in the context of the presentinvention.

FIG. 10B shows the opposite end from FIG. 10A where an exterior sill 61abuts a lower frame 62 fabricated preferably from a polyurethane productbased on rigid foam with a high thermal insulating value such asPurenit® available from Puren gmbh of Überlingen, Germany. A vaporbarrier 19 is contiguously provided under the lower frame 62 and alongthe slab 25 adjacent to foundation insulations 20, 24. In this manner,the airtight layer is formed by the double pane glass 56, spacer 55,inner door frame 57 b, and vapor barrier 19. In general, doors arepreferably placed so they bear partly or in whole on the concrete slab.

FIGS. 11A through 12D show variations substantially similar to thestructure already shown and described in FIGS. 10A and 10B, but relatedto fixed and operable windows.

FIGS. 11A and 11B are schematic cross-sectional plan views showing,respectively, a fixed window detail and an operable window detailincorporating the present invention with similar structure and functionof elements shown and described with regard to FIGS. 10A and 10B. Itshould be noted in both the placement of second sheathing layer 11extends around nailer 52 b and the insulation 53 thereby ensuring acontiguous airtight, water-repelling, vapor-open barrier to the blanketlayer in either configuration.

FIGS. 12A through 12D are substantially similar to the header and sillconfigurations of FIGS. 10A and 10B except that these additional figuresschematic cross-sectional side views showing a fixed and operable windowhead and sill details incorporating the present invention, thus partsare similarly labeled. In each, it should be understood that theairtight layer maintains the building envelope contiguously via thefirst sheathing layer 30, the plywood buck 59 suitably wrapped with aweathertight tape, the window frames (57 a through 57 c, depending uponthe fixed or operable configuration shown), and window glass 56, alongwith suitably placed taping 50 as shown.

In FIG. 13 there is shown a schematic cross-sectional side view showingan example of a floor to floor gable wall marriage detail incorporatingpanelized wall sections in accordance with the present invention. Here,“marriage joints” allowing each panel to be air-sealed and insulatedafter panel installation. Again, the panel break 200 is shown to betterview the separation between panelized wall sections. Here, the interfacebetween panelized wall sections includes a set of horizontally orientedI-joists 63, preferably formed by an 11⅞ inch I-joist arranged 24 incheson center with SPF flanges and OSB webs. Each horizontally orientedI-joist 63 perpendicularly abuts the end of each I-joist 29.

With further regard to FIG. 13, a pair of insulation boards 49 areprovided within the opposing voids in each horizontally oriented I-joist63. It should also be noted that that second sheathing layer 11 isprovided across insulation boards 49 thereby ensuring a contiguousairtight, water-repelling, vapor-open barrier to the blanket layer ineither configuration. The flooring section includes web joists 37 ofwhich the outermost one abuts the first sheathing layer 30 and restsbetween internal walls 34, specifically upon top plate 65 as shown.Taping 50 is provided at the joining of each horizontally orientedI-joist 63 against the adjacent first sheathing layer 30 to providecontiguity in the airtight layer. Extending the first sheathing layer 30above the blanket layer ends also facilitates air sealing the horizontalmarriage joint at floor-to-floor wall connections.

At wall top plates, it is also advantageous to let in strips ofair-sealing membrane to the airtight layer of each wall during wallconstruction, to be connected to the roof airtight layer duringassembly, to complete the airtight layer. As well, holding blanket layertop plates slightly lower than the roof slope is beneficial to allow fordiscrepancies in construction.

During a typical installation like that shown in FIG. 13 where apanelized wall section is installed above another such section,typically (but not limited to) second story cave walls, the structuralwall bears on top of the floor framing, but the blanket layer extendsdown below the top of the second floor. The second sheathing layer 11may extend down to meet the (typically) first floor airtight layerallowing a small construction gap, and the joint is sealed with tape.The blanket layer does not extend down as far, typically leaving a 6-8″horizontal gap to be filled with cellulose on site after air sealing iscomplete.

At gable walls, the panelized wall structures in accordance with thepresent invention may advantageously also provide for “balloon framing”of the structural wall either to span from the bottom of the first floorto the ceiling of the second floor or alternatively extending theframing to the top of the roof slope. “Balloon framing” the entire wallassembly is also possible by running structural components and blanketlayer structure the full height of the building. It is also possible toinstall and seal blocking in the stud bays, in line with the ceiling airbarrier, to allow continuity of the air barrier between ceiling andwalls.

While panelized wall sections have thus been described in detail withregard to several configurations within a building, it should further benoted that the present inventive concepts may also be provided to apanelized roof section. Accordingly, FIGS. 14 through 18 relate to thepresent invention in regard to specifics of roofing configurations.Again, like elements as previously described are shown and labeled,though not discussed again as their structure and function are aspreviously explained herein above.

With specific reference to FIG. 14, there is shown a schematiccross-sectional view through a panelized roof section incorporating thepresent invention. Just as in the panelized wall section of FIG. 2 etseq., the panelized roof section also includes elements which can begrouped into five (5) basic categories which include the structurallayer, the airtight layer, the blanket layer, the weather resistantbarrier, and the rain screen.

The structural layer of the panelized roof section shown in FIG. 14includes rafters 71 which are preferably suitable 2×10 SPF studsarranged 24-inch on center, in a commonly understood manner, ceilingstrapping 64 from 1×3 SPF is arranged 16-inch on center upon whichinternal surfacing of gypsum sheetrock 33 or any suitable interiorsurfacing product for the given implementation is affixed. Within thevoids between rafters 71, there is also provided mineral wool insulation32. The interior framing system of rafters 71 carries all structuralloads. Connection of the roof airtight layer to the wall airtight layermay be accomplished with flaps of second sheathing layer 11 that projectbelow the rafters 71.

The airtight layer provides a structural diaphragm that is also theprimary air barrier and vapor retarder on the outside of the structurallayer. In terms of FIG. 14, this is provided by root sheathing 70. Theroot sheathing 70 is preferably constructed of a suitable weathertightcoated OSB (oriented strand board) such as ⅝-inch ZIP® sheathing andrendered airtight with all joints and nail holes taped with a suitableweatherproof taping 50 such as Tescon Vana® adhesive tape with fleecebacking available from Pro Clima® or any suitable weathertight tape.

In terms of FIG. 14, the blanket layer is the insulating layer locatedexterior to the roof sheathing 70 and which includes roofing I-joists 69filled there between with cellulose insulation 14 or similar suitableinsulating material. Each roofing I-joist 69 is preferably a 16-inchI-joist arranged 24 inches on center with SPF flanges and OSB webs. Theblanket layer is structurally screwed (using structural screws) to thestructural layer as shown with taping 50 provided to render anycorresponding holes airtight as previously mentioned. It should beunderstood that sheet goods (plywood or OSB) are provided at the top andbottom of the I-joists as top and bottom plates so as to create a cavityfor blown insulation. For purposes allowing air evacuation wheninstalling blown insulation, holes may be drilled in the roofingI-joists 69 of the blanket layer and covered with air-permeable mesh.Cellulose insulation may be installed more densely than normal, at 4.0to 4.25 pounds per cubic foot, to ensure that such insulation remains inplace during transport and for the life of the building.

With continued reference to FIG. 14, the weather resistant barrier isformed by the second sheathing layer 11 which, similar to its use in thepanelized wall sections, is made of an airtight, water-repelling,vapor-open fabric that is resistant to outdoor weather. It isadvantageous that the placement of the second sheathing layer 11 is in aprotected location, above the rafters, internal to the roof assembly.

The panelized roof section shown in FIG. 14 also includes a rain screenwhich includes the outermost parts shown adjacent the exterior of thesecond sheathing layer 11. Vertical roof strapping 68 is first suitablysecured (e.g., via screws not shown) over the second sheathing layer 11and preferably formed by 1×3 SPF arranged 24″ on center to abut eachroofing I-Joist 69 as shown. Upon the vertical roof strapping 68 issecured horizontal roof strapping 66 preferably formed by 2×4 SPFpurlins arranged 12″ on center so as to create a freely drainingventilation channel. The final outer layer of roofing 67 is provided inany typical manner such as standard sheet metal rooting or as desiredfor the given building's exterior decor requirements. Installation ofroof strapping below the air barrier may be provided in a manner thickenough to allow electrical conductors to be installed while meeting codedistance for fasteners.

Panelized roof sections may be pre-insulated at the factory or postInsulated at the installation site. Leaving the ratter bays uninsulated,as a “service cavity,” until after the building envelope is complete isbeneficial so as to facilitate panel attachments, mechanical andelectrical work. Panelized roof sections that are post-insulated may beprovided in the form of prefabricated trusses that are installed, airsealed, and insulated on site, and may include structural support in theform of shop-fabricated roof trusses, air sealing in the form of amembrane below the trusses connected to the walls' airtight layer, andinsulation blown into the resulting attic cavity.

FIG. 15 is a schematic cross-sectional cave view through a panelizedroof section in conjunction with a panelized wall section, eachincorporating the present invention. Here, the interface of thepanelized roof section with the panelized wall section is configured soas to ensure that the airtight layer is contiguous and completelyuninterrupted. More specifically, the end of the panelized roof sectionis angled to provide desired pitch of roofing 67. It should be notedthat the wall rain screen cavity is connected with the roof ventilationplane for fully ventilated cladding.

A roofing rimboard 73 preferably formed of 1⅛″ OSB suitably wrapped witha weathertight tape. The roofing rimboard 73 abuts the first sheathinglayer 30 with all joints including taping 50. As well, the airtightlayer of the panelized wall section and the airtight layer of thepanelized roof section include a barrier 72 there between. The barrier72 is preferably a high performance airtight vapor control layer such asPro Clima® DA, Intello, or Intello Plus vapor retarder layers with alljoints sealed by taping 50 preferably with Tescon Vana® or Rapid Cell®tape at all seams and staples so as to provide a continuous air barrier.In this configuration, the airtight layer is formed contiguously by theroof sheathing 70, rimboard 73, barrier 72, and first sheathing layer30, and assured by taping 50.

When there are cave overhangs, it is advantageous to hold the cave wallblanket layer top plates slightly lower than the bottom of the truss topchord so as to allow the top chord to extend over the top of the blanketlayer. At cave walls and rake walls, running the blanket layervertically beyond the structural wall top plate to meet (with a smallconstruction gap) the roof plane may be accomplished for the beneficialpurpose of over-insulating the roof framing.

FIG. 16 is a schematic cross-sectional view through panelized roofsections (one in dotted line not labeled) showing ridge detail andincorporating the present invention. Here, the panelized roof sectionsattach to a ridge beam 75 using rafter hangars 74. The interface betweenpanelized roof sections atop the ridge beam 75 is seen to include a gapwhich is filled with insulation 48 which may be in the form of watercured butyl fired urethane foam which may be injected into thecorresponding space. Taping 50 over the ends of abutting roof sheathing70 ensures a contiguous airtight layer. The interface of the blanketlayers includes a vertical gap in line with the ridge beam 75 andinsulation 48, and which vertical gap is filled with celluloseinsulation 14.

It is advantageous where two roof panels meet to build one panel withextra second sheathing layer 11 so as to be unfurled and sealed to theadjacent panel after air sealing is complete. It is also advantageouswhere two roof panels meet at the ridge to leave a cavity in the blanketlayer to facilitate air sealing from above and/or to build one panelwith extra second sheathing layer 11 so as to be unfurled and sealed tothe opposite panel after air sealing is complete.

FIG. 17 is similar to FIG. 15 except that FIG. 17 includes a trussedroof. It should be readily apparent that the trussed roof includestrusses 76 that may be of any suitable design configurationcorresponding to the given building requirements. Here, the airtightlayer is provided by way of membrane 72 secured across the bottom of thegiven trusses 76 with taping 50 provided at all seams and staples. Heavyceiling strapping 77 is then attached (e.g., via screws) to trusses 76with the membrane 72 secured there between. In this configuration, theairtight layer is formed contiguously by the membrane 72 and firstsheathing layer 30, and assured by taping 50.

A 24″ raised heel truss roof is typically a cost effective approach fora trussed roof design, insulated with loose-fill cellulose to a depth of24″ to 30″ for U values ranging from 0.071 to 0.045 W/m²K (0.0125 to0.008 Btu/hr ft² ° F.). ≈R 80 to 120. The truss may be shaped like aconventional gable, or it may be a mono-pitch (aka “shed roof”),low-slope (aka “flat roof”), or other shapes. The economical choice isfor the truss to have a horizontal bottom chord, resulting in aconventional flat ceiling, but it may also be scissor or parallel chordtrusses to create cathedral ceilings.

FIG. 18 is a schematic cross-sectional view through a low slope pitchroof incorporating the present invention. Such a low slope, or flat,roof may include layers having roof sheathing 78 such as ZIP System®,fiber board 79, and EPDM (ethylene propylene diene monomer (M-class)rubber) 80 with suitable seam tape 81, drip edge 82, and fascia 83 whichare known in the low slope roofing art to provide a suitably durable lowslop roofing surface. In this configuration, a panelized roof sectionsimply abuts to a panelized wall section and rests on top plate 65 ofthe internal wall 34. In this configuration, the airtight layer isformed contiguously by the roof sheathing 70 and first sheathing layer30, and may also be assured by taping 50 over abutting ends so as toensure a contiguous airtight layer.

The wall assembly and corresponding system is certified by theInternational Passive House Institute to be free of thermal bridging,with a U-wall of 0.101 W/m²K (0.017 Btu/hr ft² ° F.), ≈R 58.6. Therelated detailing the building's exterior corners result in negative Psi(ψ) values, meaning that not only are they free of thermal bridging,they are a net gain when performing heat loss calculations. The presentinvention has a ψ at building exterior corners is −0.068 W/mK (−0.039Btu/h ft² ° F.) and at building interior corners the ψ value is 0.026W/mK (0.015 Btu/h ft² ° F.). The International Passive House Institutehas also determined the panelized roof sections to perform with a Uvalue of 0.065 W/m²K (0.011 Btu/hr ft² ° F.), ≈R 90. At the caveconnection with the exterior wall, typically a thermal bridge, theinventive roof assembly has negative thermal bridging: ψ=−0.029 W/mK. Atthe ridge, another potential source of problems, the marriage jointachieves ψ=−0.029 W/mK

As mentioned, the inventive panel assemblies (i.e., panelized wallstructures and panelized roof structures) are shop-fabricated. In otherwords, the inventive assemblies are assembled primarily in a climatecontrolled facility which ensures high quality in construction andenables tight tolerances of all assembly dimensions. Panel size for eachassembly is of course dictated by the given project's geometry,equipment constraints, and trucking restrictions. Following installationon site, each of the airtight layer, the blanket layer insulation, andthe weather resistant barrier is completed at the marriage joints. Useof a crane may facilitate panel setting, while shipping of the panelsmay be provided horizontally on a trailer. It may be preferable toutilize waler boards (i.e., framing lumber attached to stakes in theground) outside the building to brace wall panels as they are erected,as opposed to typical interior wall bracing which also advantageouslyprotects the concrete slab from damage.

With further reference to FIG. 2, it should also be noted that thefoundation insulation 20, 24 and corresponding slab 25 may provideunique innovations in the combination as shown. More specifically, araft slab foundation that is a well-insulated, self-forming foundationsystem may be provided that includes EPS foam, in customizableinterlocking shapes, to form the perimeter and “frost wing” (i.e., theportion which extends beyond the concrete slab). The customizableinterlocking shapes may interlock with the frost wing to create aperimeter form for the concrete slab. As well, the EPS foam may beprovided in simple rectangular form to create sub-slab insulation.

The foam components are prefabricated in a shop. Following sitepreparation, the foam components are set on the site, sealed togetherwith sprayed foam, the vapor barrier is installed, concrete reinforcingis installed, and the concrete slab is poured into the EPS foam “raft.”At a nominal 8″, the concrete slab is thick enough that additionalstructural support in the form of footings is not typically required.Moreover, the foam insulation protects the slab from thermal losses.Such innovative raft slab foundations may beneficially provide featuresincluding the use of borate-treated EPS foam for all components and theuse of different densities of EPS for different locations.

The shape of a “frost wing” portion of such a raft slab system mayinvolve including a wing projecting beyond the building with a groovewhich receives the slab form and sloped to shed water. The shape of the“slab form,” L-shaped in section, which interlocks with the frost wingadvantageously creates an 8″ tall form for the concrete slab. The raftslab system may feature: infilling the frost wing perimeter withrectangular blocks of borate-treated EPS foam; specific dimensioning ofall parts; using component dimensions adequate to meet the Passive Housestandard in cold climates; having all parts cut to shape and length,including mitered wings at inside and outside corners; leaving gapsbetween all components, pending application of spray foam adhesivesealant; using spray foam adhesive sealant to connect all components;using blocks of foam offcuts to support steel reinforcing before theconcrete slab is poured; following the concrete pour, wrapping the vaporbarrier membrane onto the top surface of the concrete and sealing itwith tape so as to be later connected with the wall air barrier; andbackfilling over the frost wing with soil for protection and aestheticreasons.

Still further, assemblies in accordance with the present invention mayform a pier foundation that minimizes or eliminates the use of plasticfoam and concrete, as both products have certain negative environmentalimpacts. A pier foundation utilizing helical metal piles or other formsof support, depending on various conditions, sized per building code andindustry best practices may therefore benefit from the present panelizedwall and roof structures. Above the piers, panelizing construction ofthe floor system may be provided in accordance with the same principlesand features shown and described herein above with regard to theinventive panelized wall and roof structures.

As mentioned, for projects where treading lightly on the land is a keyconcern, eliminating plastic foam is a goal, or access to the site iscompromised, a pier foundation may be used. Using helicalpiers—galvanized metal posts with an auger screw at the bottom,literally drilled into the ground—minimizes disturbance of the site. Thefloor is framed with deep I-joists and filled with dense-packedcellulose, with an airtight, moisture-repelling skin applied to thebottom of the floor system. A small, insulated chase may be used tobring utilities into a central location. The same insulated floor systemused for piers may be used on an uninsulated foundation or crawlspace.The present invention utilized with a foam-free framed floor system uses24″ I-joists filled with dense-packed cellulose, with assemblyinsulation values of 0.070 W/m²K (0.012 Btu/hr ft² ° F.), ≈R 83.3.

It should be readily understood that the present inventionadvantageously allows in-shop fabrication of building components andassemblies thus ensuring quality control and fast, accurate installationon site. As well, this allows for configuring building components andassemblies for ease of loading and trucking flat (horizontally) on aflatbed trailer. Such in-shop fabrication of building components andassemblies thereby enable building envelope performance much greaterthan that provided by standard construction techniques.

The above-described embodiments of the present invention are intended tobe examples only. Alterations, modifications and variations may beeffected to the particular embodiments by those of skill in the artwithout departing from the scope of the invention, which is definedsolely by the claims appended hereto.

What is claimed is:
 1. A system for constructing an energy efficientbuilding, said system comprising: at least one panelized structurehaving a structural layer including a first set of voids and located atan inner area of said at least one panelized structure, said inner areabeing adjacent to intended living space of said energy efficientbuilding, an airtight layer formed by a first sheathing layer providinga primary air barrier and a vapor retarder exterior to said structurallayer, a blanket layer located exterior to said first sheathing layerand formed by a plurality of vertical members with a second set of voidslocated between each of said vertical members, a weather resistantbarrier located exterior to said blanket layer and including a secondsheathing layer formed by an airtight, water-repelling, vapor-openfabric, a rain screen located exterior to said weather resistantbarrier, said rain screen being adjacent to outdoor space external tosaid energy efficient building and including a drainage plane internalthereto, said drainage plane for channeling moisture away from saidweather resistant barrier; insulation for placement within saidstructural layer and said blanket layer; and wherein said at least onepanelized structure is air-sealed and insulated within said first andsecond sets of voids after installation.
 2. The system as claimed inclaim 1 wherein at least a first panelized structure and a secondpanelized structure are provided and include a marriage jointtherebetween, said marriage joint configured to provide continuity ofsaid first sheathing layer between said first panelized structure andsaid second panelized structure and continuity of said second sheathinglayer between said first panelized structure and said second panelizedstructure.
 3. The system as claimed in claim 2 wherein said firstpanelized structure is a wall panel and said second panelized structureis a roof panel.
 4. The system as claimed in claim 3 wherein said secondpanelized structure forms a pitched roof of said energy efficientbuilding.
 5. The system as claimed in claim 3 wherein said secondpanelized structure forms a flat roof of said energy efficient building.6. The system as claimed in claim 2 wherein said first panelizedstructure and said second panelized structure are both wall panels. 7.The system as claimed in claim 6 wherein said wall panels form acontiguous straight section of wall.
 8. The system as claimed in claim 6wherein said wall panels are arranged at a right angle to one anotherand form an interior corner section of wall.
 9. The system as claimed inclaim 6 wherein said wall panels are arranged at a right angle to oneanother and form an exterior corner section of wall.
 10. The system asclaimed in claim 2 wherein said blanket layer is attached to saidstructural layer via structural screws.
 11. The system as claimed inclaim 10 wherein said airtight layer is retained in place between saidblanket layer and said structural layer via said structural screws. 12.A panelized wall structure for constructing an energy efficientbuilding, said panelized wall structure comprising: a structural layerhaving a first set of voids and located at an inner area of saidpanelized wall structure, said inner area being adjacent to intendedliving space of said energy efficient building; an airtight layer formedby a first sheathing layer providing a primary air barrier and a vaporretarder exterior to said structural layer; a blanket layer locatedexterior to said first sheathing layer and formed by a plurality ofvertical members with a second set of voids located between each of saidvertical members; a weather resistant barrier located exterior to saidblanket layer and including a second sheathing layer formed by anairtight, water-repelling, vapor-open fabric; and a rain screen locatedexterior to said weather resistant barrier, said rain screen beingadjacent to outdoor space external to said energy efficient building andincluding a drainage plane internal thereto, said drainage plane forchanneling moisture away from said weather resistant barrier.
 13. Thepanelized wall structure as claimed in claim 12 further includinginsulation located within said first and second set of voids.
 14. Thepanelized wall structure as claimed in claim 13 further including amarriage joint configured to provide continuity of said first sheathinglayer between said panelized wall structure and another first sheathinglayer of another panelized wall structure and continuity of said secondsheathing layer between said panelized wall structure and another secondsheathing layer of another panelized wall structure.
 15. The panelizedwall structure as claimed in claim 13 wherein said blanket layer isattached to said structural layer via structural screws.
 16. Thepanelized wall structure as claimed in claim 13 wherein said airtightlayer is retained in place between said blanket layer and saidstructural layer via said structural screws.
 17. A panelized roofstructure for constructing an energy efficient building, said panelizedroof structure for constructing an energy efficient building, saidpanelized roof structure comprising: a structural layer having a firstset of voids and located at an inner area of said panelized roofstructure, said inner area being adjacent to intended living space ofsaid energy efficient building; an airtight layer formed by a firstsheathing layer providing a primary air barrier and a vapor retarderexterior to said structural layer; a blanket layer located exterior tosaid first sheathing layer and formed by a plurality of vertical memberswith a second set of voids located between each of said verticalmembers; a weather resistant barrier located exterior to said blanketlayer and including a second sheathing layer formed by an airtight,water-repelling, vapor-open fabric; and a rain screen located exteriorto said weather resistant barrier, said rain screen being adjacent tooutdoor space external to said energy efficient building and including adrainage plane internal thereto, said drainage plane for channelingmoisture away from said weather resistant barrier.
 18. The panelizedroof structure as claimed in claim 17 further including insulationlocated within said first and second set of voids.
 19. The panelizedroof structure as claimed in claim 18 further including a marriage jointconfigured to provide continuity of said first sheathing layer betweensaid panelized roof structure and a corresponding first sheathing layerof a panelized wall structure and continuity of said second sheathinglayer between said panelized roof structure and a corresponding secondsheathing layer of a panelized wall structure.
 20. The panelized roofstructure as claimed in claim 18 wherein said blanket layer is attachedto said structural layer via structural screws, and said airtight layeris retained in place between said blanket layer and said structurallayer via said structural screws.